Thermal-sprayed tooling

Abstract

A metallic shell used, for example as a mold, is formed by spray deposition connected to a base by rods or other supports connected to mounting elements which are incorporated in the shell during the deposition process. The shell can incorporate different metals to provide different thermal conductivity in various regions.

1. A mold comprising:
 (a) a shell formed from a sprayed metal, said shell having a working surface conforming to the configuration of a part to be molded and having an exterior surface;  
 (b) a plurality of mounting elements embedded in said shell at spaced-apart locations;  
 (c) rods secured to said mounting elements and projecting therefrom; and  
 (d) a base connected to said rods and supporting said shell through said rods.  
 
     
     
       2. A mold as claimed in  claim 1  wherein each said mounting element has a main section extending in a first direction and defining an inner end and an outer end, and a one or more retainer sections projecting from said main section transverse to said first direction, said retainer sections being disposed within the metal of said shell, between said working and exterior surfaces. 
     
     
       3. A mold as claimed in  claim 1  wherein each said mounting element has a bore therein and said rods are received in the bores of said mounting elements. 
     
     
       4. A mold as claimed in  claim 3  wherein said bores are threaded and said rods are threadedly engaged in said bores of said mounting elements. 
     
     
       5. A mold as claimed in  claim 4  further comprising adjustable attachment elements adjustably mounted on said base, said rods being threadedly engaged with said adjustable attachment elements. 
     
     
       6. A mold as claimed in  claim 1  further comprising adjustable attachment means elements adjustably mounted on said base or said rods, at least some of said rods being connected to said base by said adjustable attachment elements, so that said adjustable attachment elements compensate for tolerances in the disposition of said rods. 
     
     
       7. A mold as claimed in  claim 1  wherein said working surface has an area of about 1 m2 or more.